EPSRC Centre for Innovative Manufacturing in Laser-based Production Processes

Abstract

A Centre for Innovative Manufacture in Laser-based Production Processes is proposed. This Centre will exploit the unique capabilities of laser light to develop new laser-based manufacturing processes, at both micro and macro levels, supported by new laser source, process monitoring and system technologies.

The past 25 years has seen industrial lasers replace many 'conventional' tools in diverse areas of manufacture, enabling increased productivity, functionality and quality, where for example laser processing (cut/join/drill/mark) has revolutionised automotive, aerospace and electronics production. However the penetration of laser technology into some areas such as welding and machining has been less than might have been anticipated. But recently there has been a significant 'step change-opportunity' to take laser-based processing to a new level of industrial impact, brought about by major advances in laser technology in two key areas:

(i) A new generation of ultra-high quality and reliability lasers based around solid state technology (laser diode and optical fibre) has evolved from developments in the telecoms sector. These lasers are leading to systems with very high levels of spatial and temporal controllability. This control, combined with advanced in-process measurement techniques, is revolutionising the science and understanding of laser material interactions. The result of this is that major improvements are being made in existing laser based processes and that new revolutionary processes are becoming viable, e.g. joining of dissimilar materials.

(ii) A new generation of high average power laser technologies is becoming available, offering controllable trains of ultrashort (picosecond and femtosecond) pulses, with wavelengths selectable across the optical spectrum, from the infrared through to the ultra-violet. Such technology opens the door to a whole range of new laser-based production processes, where thermal effects no longer dominate, and which may replace less efficient 'conventional' processes in some current major production applications.

These new developments are being rapidly exploited in other high-value manufacturing based economies such as Germany and the US. We argue that for the UK industry to take maximum advantage of these major advances in both laser material processing and machine technology there is an urgent requirement for an EPSRC Centre for Innovative Manufacturing in Laser-based Production Processes. This will be achieved by bringing together a multi-disciplinary team of leading UK researchers and key industry partners with the goal of exploiting 'tailored laser light'.

Together with our industrial partners, we have identified 2 key research themes. Theme A focuses on Laser Precision Structuring, i.e. micro-machining processes, whilst Theme B is focused on joining and additive processes. Spanning these themes are the laser based manufacturing research challenges which fall into categories of Laser Based Production Process Research and Laser Based Machine Technologies, underpinned by monitoring and control together with material science. Research will extend from the basic science of material behaviour modelling and laser-material interaction processes to manufacturing feasibility studies with industry.

The Centre will also assume an important national role. The Centre Outreach programme will aim to catalyse and drive the growth of a more effective and coherent UK LIM community as a strong industry/academia partnership able to represent itself effectively to influence UK/EU policy and investment strategy, to promote research excellence, and growth in industrial take-up of laser-based technology, expand UK national knowledge transfer and marketing events and improve the coordination and quality of education/training provision.

Planned Impact

Laser-based manufacturing is a global multi-billion dollar industry with significant business opportunities for both UK manufacturers and UK companies in the laser-based machine supply chain. Our joint industry/academic Team propose an ambitious programme of coordinated research that will enable significant business growth opportunities for our multi-national and SME partners. Furthermore, the Centre will stimulate the broader UK community, providing leadership in developing UK public policy, in providing specific hardware and infrastructure access especially for SMEs, as well as coordinating provision for education and training needs for the industry, to ensure the availability of the high engineering skill levels that sustainable growth in this technology demands.

Our business model assumes co-financing of the Centre by the universities and the EPSRC with substantial gearing on the core public investment from the partner companies and other sources as indicated below. The primary use of the core investment will be to fund the Platform and Flagship research programmes, and as the initial source of seed funding designed to broaden Centre participation and stimulate innovation among both academic and industry researchers. The main focus of the Centre research programmes will be on low TRL science-based activity aiming to generate high impact manufacturing process and supply chain technology opportunities for our industry partners, and to enhance the Centre's global reputation for research excellence.

A total of 28 UK companies have confirmed in writing their commitment to take an active role in the UK National Centre, as either core or specific project partners. The industrial foci of these companies cuts right across the value supply chain for this industry, including laser process users in diverse industrial manufacturing sectors, as well as laser source, optics and laser machine manufacturers. Moreover, core partner staff have been active participants with the academic team in formulating plans for the Platform Research portfolio and identifying the challenges which underpin the Flagship Research Themes.

Although the Centre will employ a range of exploitation strategies, the underpinning approach will be the systematic sharing of new scientific information and technology with industry partners through effective project review procedures, including project-by-project IP audits. In addition to the Core Platform and Flagship programmes, we will seek additional leverage and industry engagement by winning directly-funded, company-focussed research projects, by partnering in TSB projects and by actively promoting larger-scale EU funded programmes, utilising our well-developed European networks. We will also work with our Strategic Partners for Exploitation, the Fraunhofer-Centre for Applied Photonics (F-CAP) and the Manufacturing Technology Centre (MTC) to provide a bridge to commercial exploitation where appropriate. Overall, the Centre Team aims to build on our previous research commercialisation successes by seeking appropriate exploitation channels in consultation with our partners.

Our stated vision at the outset of the Centre was to exploit the unique features of laser light and the experience of our world-leading team to unlock manufacturing innovation and deliver ground-breaking industrial impact in key areas of the UK economy. To realise this vision we focused on science-based research, drawing on our considerable depth and breadth in physics, materials science, and mechanical/electrical/photonics engineering at the five partner universities to deliver innovative laser process and hardware solutions, thereby enabling the creation of high-impact laser-based production processes and machine technologies.

CIM-Laser supported a total of 40 separate projects, co-funded with our industrial partners. Our strategy throughout has been to combine laser material interaction fundamentals with advanced materials science to underpin the development and optimisation of laser-based manufacturing processes. We developed, initiated and delivered projects across a wide range of laser interaction timescales (from picosecond pulsed to continuous lasers) to characterise basic laser-material interactions at a fundamental level, whilst solving specific manufacturing challenges. For example, we undertook fundamental research to understand the underlying physics and hence significantly improve the yield of a novel picosecond laser welding process for direct bonding of highly dissimilar materials (such as glass and metal).

Key research highlights across CIM-Laser include: the development of a laser wire additive manufacture system capable of producing features as small as 1 mm across, suitable for applications such as the repair of turbine blades; the demonstration of laser melting systems in novel configurations including high laser power, ns pulsed systems and low atmospheric pressure systems; the development of high-energy lasers at 2 µm wavelength to enable materials processing feasibility studies; the manufacture of holographic anti-counterfeiting structures directly onto metal surfaces (as highlighted by BBC Scotland); the development of a miniaturised GHz frame rate holographic imaging system and testing of this with ultra-short pulsed laser processes including the welding of glass to metal (as highlighted by BBC Scotland); the development of a phenomenological model for laser powder bed processes, essential to understand and compensate machine-to-machine variability with powder bed additive manufacturing; and the demonstration of improved strength dissimilar welding (steel to aluminium) by pre-processing with a pulsed laser. Our Outreach Activity particularly focused on building links to the UK industrial laser, manufacturing, and academic communities beyond the cohort of our collaborators. In year one we worked with these communities to produce a UK Roadmap. Building on this, we (jointly with AILU, Association of Industrial Laser Users) formed a National Strategy Working group to develop Lasers for Productivity: a UK Strategy. This was launched at the Houses of Parliament in March 2018.

Exploitation Route

The findings are being taken forwards in a number of follow-on projects, both EPSRC, EU and Innovate UK. There has been significant interest from many different companies and other researchers in our results. Possible applications outside of those already being pursued include for example anti-counterfeiting of whisky bottles; microfluidics manufacture for medical applications; improved additive manufacturing machines.

Laser-based manufacturing: from university laboratory to industrial impact
The EPSRC Centre for Innovative Manufacturing in Laser-based Production Processes (CIM-Laser) is a 5-university Centre that over the past 5 years has played a key role in supporting an increased uptake of laser-based manufacturing in the UK. The academic partners (Heriot-Watt, Cranfield, Liverpool, Manchester and Cambridge Universities) have worked with more than 30 companies in a wide-ranging programme of coordinated industrially-focused research and network-building activities. Together with the Association of Industrial Laser Users (AILU), we have developed a national strategy for increased use of industrial lasers in the UK: Lasers for Productivity: A UK Strategy, which was launched at the Houses of Parliament in March 2018.
During the past 5 years we have delivered a significant volume of industry-focused manufacturing research, much of which is now either being transferred to industry or being further developed in follow-on EPSRC, EU and Innovate UK funded projects. We have also contributed to the development of many highly skilled people, with more than 60 researchers directly involved in CIM-Laser: 19 academic staff, 26 RAs, 12 PhD and 5 EngD students. In addition, we have funded 4 Innovation projects at Universities outside of CIM-Laser.
CIM-Laser has supported a total of 40 separate projects, co-funded with our industrial partners. Our strategy throughout has been to combine laser material interaction fundamentals with advanced materials science to underpin the development and optimisation of laser-based manufacturing processes. We developed, initiated and delivered projects across a wide range of laser interaction timescales (from picosecond pulsed to continuous lasers) to characterise basic laser-material interactions at a fundamental level, whilst solving specific manufacturing challenges. For example, we undertook fundamental research to understand the underlying physics and hence significantly improve the yield of a novel picosecond laser welding process for direct bonding of highly dissimilar materials (such as glass and metal). A selection of key research outcomes are highlighted below.
Ultrashort pulsed laser welding of glass and metal
We have worked to develop a robust process to weld optical materials, such as glasses and crystals directly to mechanical support materials such as metals (fig.1) . This process is dependent on creating the right mix of rapid absorption of the high peak power laser light leading to plasma generation, and thermal accumulation to create a suitable melt volume. Following the success of the CIM-Laser research, Heriot-Watt, Oxford Lasers and other partners developed an Innovate UK project, UltraWELD, for industrial translation of this process. This involves the development of a prototype ultra-short pulse laser welding machine by Oxford Lasers. End-users of the welding technology, Leonardo and Gooch & Housego are also involved.
Tamper-proof holographic markings for high-value metal goods
By carefully controlling the pulse energy from a nanosecond pulsed UV laser it is possible to create optically-smooth craters, a few microns wide and a fraction of a micron deep, with a high degree of dimensional control. These craters have been used as the basis of holographic structures, by creating a suitably patterned array of craters on a smooth metal surface (fig.2). When illuminated with a visible laser beam, light reflected from these craters interferes with that reflected from the unprocessed metal surface, creating a diffractive image that can be viewed on some kind of screen, e.g. a piece of paper or card, placed a short distance away. This work is now being translated to industry via further support from EPSRC (Impact Acceleration Account). A patent was filed in 2017 on techniques to hide additional information in the holograms, and we are now working with Sisma S.p.A. to incorporate the process into their laser marking machines for applications in the jewellery industry.
Holographic Diagnostics of Laser Based Processes
Laser manufacturing processes have in general been developed empirically, that is, based on observation and experience, rather than derived from theory. Whilst this approach has been very successful, the large number of variables involved means that large regions of potential parameter space remain unexplored and many processes are likely not optimised. To address this, in CIM-Laser a GHz frame rate holographic camera has been developed to provide a proper link to process and material fundamentals. This has now been commercialised by the University of Cambridge spin-out Cambridge Techworks Ltd (fig.3), who have found a ready market in laser processing research laboratories.
Wire + Laser Additive Manufacture (WLAM)
A fundamental study of this process was made within CIM-Laser, including a study of the critical parameters underpinning the process, resulting in development of a well-controlled deposition system, and demonstration of high build rate and net shape deposition. This led to additional major EPSRC and industry funding (£8.7M) for the NEWAM Programme Grant led by Cranfield University, to transform large-area metal additive manufacture, by pioneering new high build-rate wire based processes with greater precision of shape and microstructure. A key focus is to ensure guaranteed as-built structural integrity with process-independent physics-based quality control and assurance enabling low cost industrial qualification.
Multi-Laser Powder Bed Fusion
Powder bed additive manufacturing has enjoyed great commercial success in recent years, however it remains slow with builds taking many hours or days to complete. The process is also plagued by problems with residual stress which can warp parts, lead to catastrophic failure during manufacture and premature fatigue failure during operation. In CIM-Laser we have developed equipment and processes to measure the effectiveness of a multi-laser powder bed process, and instigated the development of new high-throughput melting strategies that also minimise residual stress. This has contributed to the development of a new AM platform by Renishaw (fig.4), and the University of Liverpool is continuing to work closely with Renishaw to ensure that developments made are transferred rapidly into products.
Refractory Material Laser Powder Bed Fusion
Refractory metals such as tungsten and niobium are extraordinarily resistant to wear and high temperature, because of this they are important high-value materials. However, their high temperature properties means that are very difficult to process using additive manufacturing. By carrying out detailed process development supported by fundamental knowledge we have defined parameters suitable for these materials. We have designed and modified the production equipment to allow this and identified stable processing regimes to allow effective production. A further 2 year project has been secured to transfer process knowledge to a commercial platform (RenAM 500M), and the industrial partners have reported that they are adapting the technology to replace conventional and expensive manufacturing routes.

The project evaluated the possibility of joining thin sheet of dissimilar alloys in overlap configuration. The research team focused on understanding laser metal interaction for the two alloys separately and then the possibility of joining these two alloys in dissimilar configuration was evaluated. Fe and Al atoms on interaction forms intermetallic compounds (IMC) which are very hard and often results in cracking near the interface due to formation of such intermetallic alloys. application of the latest generation pulsed laser which has pulse energy in the range of (~1 mJ) but very high repetition rate, may able to overcome the problem of IMC formation by fast freezing weld pool which prevents inter-diffusion of the two dissimilar alloys. The research team worked evaluated the thickness range that can be welded by such pulse energy and evaluate the strength of the dissimilar joint under different welding conditions and by different weld lengths.

Collaborator Contribution

Our partner provided the laser to perform the welds and gave us input regarding the performance of the laser under different operating conditions and also shared information on research effort on dissimilar joining of different alloy combinations at their premises

Impact

- Two Masters project
- SPI is now strategic partners with CU in a number of laser processing related projects, the main one being an Innovate, UK sponsored project on joining of tab to end of extremely thin Al alloy (Environment Domed End)

This project will develop a novel 3D freeform fabrication laser based manufacturing platform. The philosophy behind this is to provide a flexible platform combining the ability to construct, build and add material to freeform shapes with metrology of the created part and the ability to remove material to achieve a high level of form fit and low tolerances in excess of that achievable in freeform manufacture on its own. By integrating fibre delivered laser sources into a parallel robot device we

Collaborator Contribution

Renishaw's in kind contribution has £50k of staff time to advise and support the project. Visit to Rensiahw head quarters is planned for Autmun 2014. The contribution for Renishaw consists of 3 paralell robots systems.

Impact

None to date, but potential for new product line and greater presence in additive manufacturing market.

Renishaw have committed cash support to this project of £24k, given their interest in replacing conventional bonding techniques in their current manufacturing processes which rely on intermediate bonding layers.

AWE plc have indicated an urgent need to develop laser based methods for the removal of thin metallic protective layers, such as Ag, from a metallic substrate material. Laser Induced Breakdown Spectroscopy [LIBS] is an established tool for the identification of metals in laser plasmas and it is proposed to use LIBS as a process monitor to detect removal of the protective layer material.

Collaborator Contribution

AWE have provided samples.

Impact

N/A

Start Year

2014

Description

Industry contribution to sub-project CfIM_07 'Laser Finishing'

Organisation

Atomic Weapons Establishment

Country

United Kingdom

Sector

Private

PI Contribution

Work is underway to investigate the feasibility of using laser processing for post-machining of parts manufactured by powder bed and wire based additive manufacturing processes. A range of different laser ablation and smoothing approaches are being tested for materials of interest for additive processes, including stainless steel, cobalt-chrome alloy, aluminium and titanium. The work to date has focused on post-processing, however it is planned to also explore in-situ inter-processing approaches. Many applications e.g. medical require a reasonably polished surface finish (i.e. good micro-roughness), so there is a particular focus on laser polishing processes. An experimental optimization of pulsed fibre laser polishing on martensitic stainless steel surfaces has provided reductions in the surface average micro-roughness (spatial ? < 10 µm) of around 80%, however the meso- and macro-roughness (10 µm < spatial ? < 80 µm and spatial ? > 80 µm, respectively) have not been affected. A combination of laser micro-machining and laser melting is currently being explored to provide improved independent control of micro, meso and macro-roughnesses.

Collaborator Contribution

Fortnightly project review meetings at Heriot Watt University with Renishaw Plc
AWE/Heriot Watt University strategic alliance workshop
EPSRC CIM for Laser-Based Production Processes Research Assistants meeting at Cranfield University (Meeting with John Barr, Selex ES UK) 03.09.2014
Various lab visits at our site

Impact

IP has been generated in the form of processing parameters

Start Year

2014

Description

Industry contribution to sub-project CfIM_07 'Laser Finishing'

Organisation

Renishaw PLC

Country

United Kingdom

Sector

Private

PI Contribution

Work is underway to investigate the feasibility of using laser processing for post-machining of parts manufactured by powder bed and wire based additive manufacturing processes. A range of different laser ablation and smoothing approaches are being tested for materials of interest for additive processes, including stainless steel, cobalt-chrome alloy, aluminium and titanium. The work to date has focused on post-processing, however it is planned to also explore in-situ inter-processing approaches. Many applications e.g. medical require a reasonably polished surface finish (i.e. good micro-roughness), so there is a particular focus on laser polishing processes. An experimental optimization of pulsed fibre laser polishing on martensitic stainless steel surfaces has provided reductions in the surface average micro-roughness (spatial ? < 10 µm) of around 80%, however the meso- and macro-roughness (10 µm < spatial ? < 80 µm and spatial ? > 80 µm, respectively) have not been affected. A combination of laser micro-machining and laser melting is currently being explored to provide improved independent control of micro, meso and macro-roughnesses.

Collaborator Contribution

Fortnightly project review meetings at Heriot Watt University with Renishaw Plc
AWE/Heriot Watt University strategic alliance workshop
EPSRC CIM for Laser-Based Production Processes Research Assistants meeting at Cranfield University (Meeting with John Barr, Selex ES UK) 03.09.2014
Various lab visits at our site

The overall goal of this project is to make the powder-based laser additive manufacturing process more robust and transferable between different powder bed systems.
This is planned to be achieved by:
• Investigation of conduction laser welding in terms of fundamental interaction parameters of spatial distribution of laser energy on the workpiece;
• Identification of laser system-independent parameters that control depth of penetration and weld bead profile during powder melting;
• Development of a phenomenological model of weld bead profile and depth of penetration in powder melting for various beam diameters;
• Identification of the most optimum conditions for different build-up strategies i.e. maximum deposition rate or maximum resolution;
• Investigation of the effect of powder grade (particle size etc) on fusion characteristics in additive manufacturing;
• Investigation of the effect of thermal properties of powder on fusion characteristics and the main differences to conduction welding in solid materials

The overall goal of this project is to make the powder-based laser additive manufacturing process more robust and transferable between different powder bed systems.
This is planned to be achieved by:
• Investigation of conduction laser welding in terms of fundamental interaction parameters of spatial distribution of laser energy on the workpiece;
• Identification of laser system-independent parameters that control depth of penetration and weld bead profile during powder melting;
• Development of a phenomenological model of weld bead profile and depth of penetration in powder melting for various beam diameters;
• Identification of the most optimum conditions for different build-up strategies i.e. maximum deposition rate or maximum resolution;
• Investigation of the effect of powder grade (particle size etc) on fusion characteristics in additive manufacturing;
• Investigation of the effect of thermal properties of powder on fusion characteristics and the main differences to conduction welding in solid materials

The overall goal of this project is to make the powder-based laser additive manufacturing process more robust and transferable between different powder bed systems.
This is planned to be achieved by:
• Investigation of conduction laser welding in terms of fundamental interaction parameters of spatial distribution of laser energy on the workpiece;
• Identification of laser system-independent parameters that control depth of penetration and weld bead profile during powder melting;
• Development of a phenomenological model of weld bead profile and depth of penetration in powder melting for various beam diameters;
• Identification of the most optimum conditions for different build-up strategies i.e. maximum deposition rate or maximum resolution;
• Investigation of the effect of powder grade (particle size etc) on fusion characteristics in additive manufacturing;
• Investigation of the effect of thermal properties of powder on fusion characteristics and the main differences to conduction welding in solid materials

For laser cutting monitoring and pierce detection the aims are:
o Measure the back reflected laser light during the cutting process and correlate the signal with the cutting process stability.
o Study the effect of the laser beam geometry, Gaussian and doughnut shape, on the cutting quality/stability.
In laser welding, the aims are:
o Extend the power factor model developed by Cranfield University to laser beam diameters smaller than 400 um and different materials.
o Develop an Expert Laser System in collaboration with JK Lasers to integrate the power factor model into the control software of the laser and ease the selection of the laser parameters according to the user requirements.

Collaborator Contribution

JK Lasers have donated a 3kW laser with multiple fibre delivery to the Centre along with welding and cutting heads, Attendance at project review meetings, additional in-kind contributions throughout the project, lab visits, etc. JK Lasers hosted a visit by all research fellows within the Centre

Impact

The Expert System will give JK Lasers a unique capability in the technology provision for laser welding systems. Similarly the pierce detection system for cutting will give them a significant technological advantage compared to their competitors.

SPI Lasers and Cranfield University are collaborating through a Knowledge Transfer Partnership to advance application of the state of the art lasers and welding processes for joining of similar and dissimilar alloy combinations with a specific target to increase the application of laser processing in the e-mobility sector. The research team at Cranfield University is working in the area of innovative laser processing and joining of dissimilar alloys for over last 6 years. The Center for Innovative Manufacture using Laser (CIM_L) grant is laser processing and joining of thin alloys played a major role in creating larger collaboration opportunity. The advancement of understanding in dissimilar joining at a fundamental level is a important factor for recognizing the research team at Cranfield as an internationally leading expert in this area.

Collaborator Contribution

SPI Lasers are inventing the state-of-the-art in laser processing by creating single mode CW and pulsed lasers for advanced processing. They are also developing their customer base through strategic and application oriented tailored joining and processing using lasers.

Impact

A KTP position was created. A suitable researcher for this position is being recruited.

Application of pulsed fibre lasers for dissimilar joining of aluminium to copper. Experiments performed as a Masters group project work at Cranfield University with very useful results. In process of publication.

Collaborator Contribution

SPI Laser, UK and Welding Engineering and Laser Processing Centre of Cranfield University works very closely in a range of different projects. One of the major area where we collaborate is in evaluating the different potential applications of the state-of-the-art fibre laser that SPI developed. One of the major thematic area is dissimilar joining of very thin metallic components for applications in battery, automobile, electronics and other consumer sectors. SPI initially provided us with the laser and we also worked in close relationship through the Centre for Innovative Manufacturing using Laser. This close collaboration benefits us from having lasers for research purposes and also most importantly understanding the application area from the customer base of SPI.

Impact

Three presentations will be made in the LPM2018 - Laser Precision Micro-fabrication Symposium 2018 to be held at Edinburgh in June. SPI is an active member and support our hub proposal bid and also we are planning to have a Research Associate as Knowledge Transfer Partner between Cranfield and SPI.

Start Year

2016

Description

Laser texturing of steel for improving the mechanical strength of the dissimilar metal laser spot welded joints of steel to aluminium

Organisation

Heriot-Watt University

Department

School of Engineering & Physical Sciences

Country

United Kingdom

Sector

Academic/University

PI Contribution

A seedcorn project for 4 months has been performed to evaluate the applicability of laser surface texturing, in order to improve the surface energy, towards joining of highly dissimilar alloys

Collaborator Contribution

The researcher from HW was involved in forming the textured surface with the application of laser and researchers from Cranfield University were engaged in dissimilar joining

Impact

A technical paper has been submitted and in future this may form part of greater proposals in the area of joining of dissimilar materials

Start Year

2015

Description

Laser welding of Al to Mg

Organisation

Nanjing Tech University

Country

China

Sector

Academic/University

PI Contribution

This project specifically investigated the application of the latest generation fibre pulsed lasers and continuous wave lasers in dissimilar joining of aluminium to magnesium for electronic applications. At Cranfield University all the experiments were performed using CW and pulsed lasers. Different interlayers were experimented with to understand their suitability in forming a robust joining solution for these two alloys

Collaborator Contribution

At Nanjing University, all the characterisations were performed. The researcher is a PhD student from the collaborating University

Impact

Not as yet but journal articles are being written

Start Year

2016

Title

Laser beam amplification by homogenous pumping of an amplification medium

Description

Apparatus 10 for amplifying a laser beam using a pump beam, comprised of a plurality of source beams 22, through an amplification medium 14; the amplification medium is pumped via a pump module 16 having a laser diode bar 18 and an optical assembly 30; the optical assembly has a first lens acting as a fast axis collimator 34 (Figure 3b), an array of second lenses acting as slow axis collimators 42 and a third focusing lens acting in both the fast and slow axis 36; the lenses are spaced so that the individual source beams from the emitters are imaged upon a facet of the amplification medium, are sized to fill the facet and overlap on the facet. In one embodiment the amplification medium is rectangular and has a long edge and a short edge oriented parallel to the slow axis and fast axis of the laser diode bar respectively. In another embodiment the source beams are directed so that peripheral source beams undergo total internal reflection on entering the amplification medium. In one embodiment several pump beams are imaged onto the amplification medium.

A lab tour and demonstration of laser marking will be part of the event "Festival of flight 2016" held in Cranfield University. Souvenirs and a demonstrator will be produced for the event.(Cranfield)

Form Of Engagement Activity

Participation in an open day or visit at my research institution

Part Of Official Scheme?

No

Geographic Reach

Regional

Primary Audience

Public/other audiences

Results and Impact

A lab tour and demonstration of laser marking will be part of the event "Festival of flight 2016" held in Cranfield University. Souvenirs and a demonstrator will be produced for the event.(Cranfield). Promotion of the CIM LbPP. Dissemination of the projects investigated within the CIM aimed at public including children

Year(s) Of Engagement Activity

2016

Description

A talk given before the industrial laser users association on the fundamentals of laser metallic powder interaction by Wasiu Ayoola

Form Of Engagement Activity

A talk or presentation

Part Of Official Scheme?

No

Geographic Reach

International

Primary Audience

Professional Practitioners

Results and Impact

Wasiu Ayoola is a PhD student in the Cranfield University and he presented his research work on fundamental laser- metal powder interaction before the industrial laser users

Year(s) Of Engagement Activity

2015

Description

A visiting researcher from Brazil came to Cranfield to investigate the feasibility of using laser plus wire additive manufacturing for repairing of turbine blades

Form Of Engagement Activity

A formal working group, expert panel or dialogue

Part Of Official Scheme?

No

Geographic Reach

International

Primary Audience

Professional Practitioners

Results and Impact

A visiting researcher from Brazil came to Cranfield to investigate the feasibility of using laser plus wire additive manufacturing for repairing of turbine blades. Collaborative research on application of laser plus wire to build worn turbine blades. Discussion of possible collaboration. Promotion of the CIMlbPP

Year(s) Of Engagement Activity

2016

Description

A visiting researcher from China came to Cranfield to investigate laser welding of magnesium to aluminium

Form Of Engagement Activity

A formal working group, expert panel or dialogue

Part Of Official Scheme?

No

Geographic Reach

International

Primary Audience

Professional Practitioners

Results and Impact

A visiting researcher from China came to Cranfield to investigate laser welding of magnesium to aluminium. Collaborative research on application of laser to weld thin sheets of magnesium to aluminium. Promotion of the CIMlbPP

Additive Manufacturing Seminars organised by Centre for Industrial Photonics, seminar series designed to connect various research centres aiming to provide a more connected AM academic landscape

Year(s) Of Engagement Activity

2017

Description

Arrangement to include the laser lab into the interactive map of Cranfield University campus - 360° pictures of the laser lab and videos showing the lasers in operation. (Cranfield)

Form Of Engagement Activity

Participation in an open day or visit at my research institution

Part Of Official Scheme?

No

Geographic Reach

International

Primary Audience

Third sector organisations

Results and Impact

Arrangement to include the laser lab into the interactive map of Cranfield University campus - 360° pictures of the laser lab and videos showing the lasers in operation. (Cranfield). The virtual open day platform will enable prospective students and companies to explore the laboratory and see examples of laser processing.

The Welding Engineering and Laser Processing Center (WELP) of Cranfield University is a more familiar name to the wider laser processing community and the center is submitting more proposals in the area of advancing laser processing of materials.

Two presentations were made at the LSP 2018 conference at Singapore on the following topics;- Application of Laser peening to induce grain refinement in wire plus arc additive built structures - Application of laser peening in improving fatigue life of aircraft fuselage structural joint

Year(s) Of Engagement Activity

2018

Description

Conference - Open day

Form Of Engagement Activity

Participation in an open day or visit at my research institution

Part Of Official Scheme?

No

Geographic Reach

National

Primary Audience

Postgraduate students

Results and Impact

PhD Poster presentation day at Cranfield University to "Promote the CIMHighlight capabilities and achievements of the Centre work at Cranfield"

Conference - Open day - Display of Masters programme - Group project presented on "Dissimilar welding of thin metallic sheets using fibre pulsed laser" plus contributions made in PhD poster presentation day

Form Of Engagement Activity

A talk or presentation

Part Of Official Scheme?

No

Geographic Reach

International

Primary Audience

Industry/Business

Results and Impact

Group worked on a project sponsored by SPI Lasers on dissimilar joining of thin structural alloys. The project led to further projects and ongoing collaborative activities in this area and finally in a KTP project in 2019.

Visit to various industrial companies and research institutions in India (IIT Bombay, IIT Indore and CMTI Bangalore) - presentations given and applications of the technology discussed

Year(s) Of Engagement Activity

2016

Description

Industrial Advisory Board

Form Of Engagement Activity

A formal working group, expert panel or dialogue

Part Of Official Scheme?

No

Geographic Reach

National

Primary Audience

Professional Practitioners

Results and Impact

Industrial Advisory Board Meeting

Year(s) Of Engagement Activity

2016

Description

Industrial Advisory Board Meeting

Form Of Engagement Activity

A formal working group, expert panel or dialogue

Part Of Official Scheme?

No

Geographic Reach

National

Primary Audience

Professional Practitioners

Results and Impact

Meeting of the Industrial Advisory Board for CIM-Laser

Year(s) Of Engagement Activity

2016

Description

Industrial engagement workshop

Form Of Engagement Activity

Participation in an activity, workshop or similar

Part Of Official Scheme?

No

Geographic Reach

National

Primary Audience

Industry/Business

Results and Impact

Industrial Engagement works hosted by University of Cambridge chaired by D P Hand

Year(s) Of Engagement Activity

2017

Description

Industrial tour and visit by AWE, UK and US delegates

Form Of Engagement Activity

Participation in an activity, workshop or similar

Part Of Official Scheme?

No

Geographic Reach

International

Primary Audience

Industry/Business

Results and Impact

The current/finished projects with AWE and their future requirements discussed - Two visits by AWE one with UK and US delegates and the other one solely with UK delegates

Year(s) Of Engagement Activity

2017

Description

Industry visit

Form Of Engagement Activity

Participation in an open day or visit at my research institution

Part Of Official Scheme?

No

Geographic Reach

Regional

Primary Audience

Industry/Business

Results and Impact

Visit by BAE for tour of labs

Year(s) Of Engagement Activity

2018

Description

International Symposium on Additive Manufacturing @ Taiwan, 2014

Form Of Engagement Activity

Participation in an activity, workshop or similar

Part Of Official Scheme?

Yes

Geographic Reach

International

Primary Audience

Policymakers/politicians

Results and Impact

Organised by the British Trade & Cultural Office (BTCO), Additive Manufacturing Association of Taiwan (AMAT) and National Taiwan University of Science and Technology (NTUST), the 1st Additive Manufacturing and 3D Printing International Conference was held at NTUST in Taipei on 3 March 2014. This conference convened international academic representatives and AM vendors together to present the most up-to-date technology, application and market trends. The UK Additive Manufacturing Mission of 5 academic and industrial speaking delegates including Dr Chris Sutcliffe, from the University of Liverpool, key partner in the Centre for Innovative Manufacturing in Laser-based Production Processes, and a technical representative for Renishaw UK - a major global AM vendor. Organised by the British Trade & Cultural Office (BTCO), Additive Manufacturing Association of Taiwan (AMAT) and National Taiwan University of Science and Technology (NTUST), the 1st Additive Manufacturing and 3D Printing International Conference was held at NTUST in Taipei on 3 March 2014. This conference convened international academic representatives and AM vendors together to present the most up-to-date technology, application and market trends. The UK Additive Manufacturing Mission of 5 academic and industrial speaking delegates including Dr Chris Sutcliffe, from the University of Liverpool, key partner in the Centre for Innovative Manufacturing in Laser-based Production Processes, and a technical representative for Renishaw UK - a major global AM vendor.

Visit by Jaguar Land Rover technical people from Power Train Division and Chassis division to see resources, facilities, present research activities and discuss their future needs.

Year(s) Of Engagement Activity

2017

Description

Jaguar Landrover (chassis division)

Form Of Engagement Activity

Participation in an open day or visit at my research institution

Part Of Official Scheme?

No

Geographic Reach

National

Primary Audience

Industry/Business

Results and Impact

Jaguar Landrover (chassis division), Presentations, lab visit and exhibition of demonstrators then discussions to highlight capabilities and achievements of the Centre work at CranfieldDiscussion about collaboration "

Year(s) Of Engagement Activity

2017

Description

Jaguar Landrover (power trains division)

Form Of Engagement Activity

A talk or presentation

Part Of Official Scheme?

No

Geographic Reach

National

Primary Audience

Industry/Business

Results and Impact

Jaguar Landrover (power trains division), Presentation of our work on laser processing which led to a research project

Lab demonstration of laser welding, marking, test bench for fibres and laser beam characterization at Cranfield's laboratory (Cranfield). Dissemination of the CIM LbPPThe students learnt about laser processing and its advantages, limitations and applications, and techniques for laser beam characterization

Exhibition stand for CIM-Laser at the World of Photonics Exhibition. There was significant interest in the stand and the work we were presenting. This allowed us to engage more broadly with industry, in particular those people who would not normally attend conferences.

Organising Committee for ILAS 2015, including sponsorship of visit by Prof Craig Arnold Princeton University

Form Of Engagement Activity

Participation in an activity, workshop or similar

Part Of Official Scheme?

No

Geographic Reach

National

Primary Audience

Industry/Business

Results and Impact

ILAS is an industrial-academic conference held every 2 years, with the primary organiser being the Association of Industrial Laser Users. CIM-Laser helped with organisation of this event, and sponsored a high profile speaker from Princeton University.

Presentation in the showcase event helped in outreaching the research outcome to a wider audience and decision makers (higher management) in AWE plc.

Such activity reinforced the strategic alliance between Cranfield and AWE and presently Welding Engineering and Laser Processing Centre is having more than one collaborative project with AWE

Year(s) Of Engagement Activity

2013

Description

PowderMET 2017 - Presentation

Form Of Engagement Activity

A talk or presentation

Part Of Official Scheme?

No

Geographic Reach

National

Primary Audience

Industry/Business

Results and Impact

PowderMET 2017 - Presentation by Alfred T Sidambe

Year(s) Of Engagement Activity

2017

Description

Presence at Scottish Manufacturing Advisory Service

Form Of Engagement Activity

Participation in an activity, workshop or similar

Part Of Official Scheme?

No

Geographic Reach

National

Primary Audience

Industry/Business

Results and Impact

Scottish Manufacturing Advisory Service - Promotion of the CIM LbPP by RES colleagues

Year(s) Of Engagement Activity

2016

Description

Presentation at International Symposium on Fusion Nuclear Energy, Kyoto, Japan

Form Of Engagement Activity

A talk or presentation

Part Of Official Scheme?

No

Geographic Reach

International

Primary Audience

Industry/Business

Results and Impact

Presentation at International Symposium on Fusion Nuclear Energy, Kyoto, Japan, aimed at Academia, industry and fusion energy community

Year(s) Of Engagement Activity

2017

Description

Presentation at the Liverpool Enterprise Forum - Prof Chris Sutcliffe

Form Of Engagement Activity

A talk or presentation

Part Of Official Scheme?

No

Geographic Reach

Local

Primary Audience

Industry/Business

Results and Impact

Presentation at the Liverpool Enterprise Forum

Year(s) Of Engagement Activity

2017

Description

Presentation before the Industrial Laser Application Symposium

Form Of Engagement Activity

A talk or presentation

Part Of Official Scheme?

No

Geographic Reach

International

Primary Audience

Professional Practitioners

Results and Impact

A presentation given and a paper published in the ILAS 2015 proceeding

Year(s) Of Engagement Activity

2015

Description

Presentations and lab visit

Form Of Engagement Activity

Participation in an open day or visit at my research institution

Part Of Official Scheme?

No

Geographic Reach

International

Primary Audience

Industry/Business

Results and Impact

NEWAM open day to discuss the activities related to additive manufacture with industrial and academic partners

Year(s) Of Engagement Activity

2019

Description

Presented before the industrial laser user association on the "Science underpinning: the route to laser based manufacturing success" by Prof Stewart Williams

Form Of Engagement Activity

A talk or presentation

Part Of Official Scheme?

No

Geographic Reach

International

Primary Audience

Professional Practitioners

Results and Impact

A talk was given before the industrial laser users association in the Industrial Laser Application Symposium 2015 with the aim of increasing the application of laser for different metal processing activities

Year(s) Of Engagement Activity

2015

Description

Public lecture hosted by the Royal Scottish Society of Arts

Form Of Engagement Activity

A talk or presentation

Part Of Official Scheme?

No

Geographic Reach

Regional

Primary Audience

Public/other audiences

Results and Impact

Public lecture hosted by the Royal Scottish Society for the Arts, on 26 March 2018

This is a highlight talk before the Materials society attended the Euromat 2015 conference

Year(s) Of Engagement Activity

2015

Description

Talk at EU HiLASE facility on diagnostics of high power processes

Form Of Engagement Activity

A talk or presentation

Part Of Official Scheme?

No

Geographic Reach

International

Primary Audience

Industry/Business

Results and Impact

Invited talk in Prague discussing advances in industrial diagnostics with a view to identifying future partners

Year(s) Of Engagement Activity

2017

Description

Talk at ICALEO 2016 conference (Cranfield)

Form Of Engagement Activity

A talk or presentation

Part Of Official Scheme?

No

Geographic Reach

International

Primary Audience

Industry/Business

Results and Impact

Talk at ICALEO 2016 conference (Cranfield) . Promotion of the CIM

Year(s) Of Engagement Activity

2016

Description

Ted-X talk, Ultra Fast Laser Processing, Richard M Carter

Form Of Engagement Activity

A broadcast e.g. TV/radio/film/podcast (other than news/press)

Part Of Official Scheme?

No

Geographic Reach

National

Primary Audience

Schools

Results and Impact

TedX talk to wide ranging audience from children to adults

Year(s) Of Engagement Activity

2016

Description

The Origin and Effect of HAZ Banding in large Scale Wire-Arc Additive Manufacture with Ti-6Al-4V, Invited Talk Phil Prangnell

Form Of Engagement Activity

Participation in an activity, workshop or similar

Part Of Official Scheme?

No

Geographic Reach

International

Primary Audience

Professional Practitioners

Results and Impact

discussions on possible future collaborations

Year(s) Of Engagement Activity

2016

Description

Tour of University of Liverpool's Additive Manufacturing Facilities given to delegation from Sci-Tech Daresbury(Science and Technology Facilities Council funded research innovation campus in Cheshire)

Form Of Engagement Activity

Participation in an open day or visit at my research institution

Part Of Official Scheme?

No

Geographic Reach

Regional

Primary Audience

Professional Practitioners

Results and Impact

Tour of University of Liverpool's Additive Manufacturing Facilities given to delegation from Sci-Tech Daresbury(Science and Technology Facilities Council funded research innovation campus in Cheshire). Discussions round Possible future collaborations

Year(s) Of Engagement Activity

2016

Description

UK Launch Event -Lasers for Productivity, A National Strategy

Form Of Engagement Activity

Participation in an activity, workshop or similar

Part Of Official Scheme?

No

Geographic Reach

National

Primary Audience

Policymakers/politicians

Results and Impact

UK Launch Event -Lasers for Productivity, A National Strategy, led in Portcullis House, Westminster and attended by industrial partners and MP's and hosted by AILU

University of Liverpool Healthcare Branding Day - Lab tours and demonstration.

Form Of Engagement Activity

Participation in an open day or visit at my research institution

Part Of Official Scheme?

No

Geographic Reach

Regional

Primary Audience

Industry/Business

Results and Impact

University of Liverpool Healthcare Branding Day - Lab tours and demonstration.- Ian Ashton

Year(s) Of Engagement Activity

2017

Description

University of Liverpool Physics Departmental Visit (Liverpool)

Form Of Engagement Activity

Participation in an activity, workshop or similar

Part Of Official Scheme?

No

Geographic Reach

National

Primary Audience

Professional Practitioners

Results and Impact

University of Liverpool Physics Departmental Visit (Liverpool). The physics department at the University of Liverpool has a large research portfolio regarding the design of detectors for nuclear physics applications. They are interested in manufacturing components in Tungsten due to its ability to block X-rays. Interest arose due a CIM project which is developing this material for additive manufacturing. Looking at future collaboration

A visit to the Centre at Cranfield University was made by Iain Wright MP, Shadow Minister for Industry. He was given a tour around the Centre facilities and met Centre researchers. The impact of the centre on industry was discussed.

Visit to HiDepAM partner in India to promote CIM LbPP and exchange knowledge in laser plus wire additive manufacturing (Cranfield). Researchers and students from the universitiesVisit to IIT Bombay, IIT Indore and CMRI Bangalore,

Year(s) Of Engagement Activity

2016

Description

Visit to RAL to discuss collaboration on laser peening

Form Of Engagement Activity

Participation in an activity, workshop or similar

Part Of Official Scheme?

No

Geographic Reach

National

Primary Audience

Industry/Business

Results and Impact

Visit to RAL to discuss collaboration on laser peening

Year(s) Of Engagement Activity

2017

Description

Visit to Stryker Orthopaedics Cork Ireland - Prof Chris Sutcliffe

Form Of Engagement Activity

A talk or presentation

Part Of Official Scheme?

No

Geographic Reach

International

Primary Audience

Industry/Business

Results and Impact

Stryker Cork is the worlds largest metal AM facility. The presentation given detailed the work that has been done in the centre

Year(s) Of Engagement Activity

2017

Description

Visit to Tampere University

Form Of Engagement Activity

Participation in an activity, workshop or similar

Part Of Official Scheme?

No

Geographic Reach

International

Primary Audience

Professional Practitioners

Results and Impact

Discussion about possible collaboration

Year(s) Of Engagement Activity

2016

Description

Visitors from Petronas Group, Malaysia

Form Of Engagement Activity

Participation in an open day or visit at my research institution

Part Of Official Scheme?

No

Geographic Reach

International

Primary Audience

Industry/Business

Results and Impact

Presentations and lab visit

Year(s) Of Engagement Activity

2017

Description

Walking Tour of Cranfields Laboratory

Form Of Engagement Activity

Participation in an open day or visit at my research institution

Part Of Official Scheme?

No

Geographic Reach

International

Primary Audience

Industry/Business

Results and Impact

Walking Tour of Cranfields Laboratory - members from General Electric

Year(s) Of Engagement Activity

2016

Description

Walking tour of Cranfield's laboratory

Form Of Engagement Activity

Participation in an open day or visit at my research institution

Part Of Official Scheme?

No

Geographic Reach

Regional

Primary Audience

Industry/Business

Results and Impact

Walking tour of Cranfield's laboratory by uk manufacturer

Year(s) Of Engagement Activity

2016

Description

Walking tour of Cranfield's laboratory by Christ White MP

Form Of Engagement Activity

Participation in an open day or visit at my research institution

Part Of Official Scheme?

No

Geographic Reach

National

Primary Audience

Policymakers/politicians

Results and Impact

promotion of CIM LbPP to Chris White MP

Year(s) Of Engagement Activity

2016

Description

Walking tour of Cranfield's laboratory was part of the "IMTMA CEOs Technology Mission to Aerospace Industries in Europe" conference

Form Of Engagement Activity

Participation in an open day or visit at my research institution

Part Of Official Scheme?

No

Geographic Reach

International

Primary Audience

Professional Practitioners

Results and Impact

Walking tour of Cranfield's laboratory was part of the "IMTMA CEOs Technology Mission to Aerospace Industries in Europe" conference. Indian delegation (CEOs, managing directors, senior advisor or Vice president) representing different organizations

Year(s) Of Engagement Activity

2016

Description

Workshop in London - lessons learnt from strategy like initiatives (CF) (HWU)